Apparatus and methods for the production of ammonia and fischer-tropsch liquids

ABSTRACT

A gasification plant and methods for producing ammonia, Fischer-Tropsch fuels, electrical power, and/or sulfur from carbon-bearing feedstocks including coal and/or petroleum coke. Methods for production of desired relative amounts of ammonia and Fischer-Tropsch liquid hydrocarbons by adjusting the amount of synthesis gas bypassing the Fischer-Tropsch reactor. The multi-product and integrated plants may be used to reduce the amount of CO 2  vented into the atmosphere during the production of these products.

CROSS-REFERENCE TO RELATED APPLICATIONS

This non-provisional utility application is a continuation of U.S.patent application Ser. No. 11/004,036, filed Dec. 3, 2004, which claimspriority to U.S. Provisional Application No. 60/526,515 filed Dec. 3,2003.

INCORPORATION BY REFERENCE STATEMENT REGARDING FEDERALLY SPONSOREDRESEARCH OR DEVELOPMENT

Not Applicable.

FIELD OF THE INVENTION

The present invention relates generally to the field of syngasgenerators, such as reformers and gasifiers of hydrocarbon fluids andsolid carbonaceous materials, and Fischer-Tropsch (FT) units primarilyfor creating liquid hydrocarbons from syngas. Syngas generators, FT, andammonia synthesis are combined to create an integrated plant forproviding one or more of ammonia, carbon dioxide, electric power, andeven sulfur when dealing with sulfur-containing raw material.

BACKGROUND OF THE INVENTION

Our modern civilization cannot be sustained without burning carbonaceousmaterials for primarily motive and electrical power within theforeseeable future. The carbon dioxide (CO₂) generated by such burningmay be contributing to the gradual increase of the planet's temperaturesince 1900. This is occurring because CO₂ permits the sun's energy topass through the atmosphere, but traps the longer wavelength energyradiated by the earth into the atmosphere.

The integrated plants and processes of this invention can help reducethe amount of CO₂ currently vented into the air as a by-product ofsynthesizing the various products later discussed in the description ofthe manufacturing plant flow diagrams. Consequently, the reduction ofCO₂, which is a greenhouse gas, through the sequestration processesdetailed herein, reduces the amount of greenhouse gases vented into theatmosphere. Further, the plants of this invention produce substantialenergy savings by balancing exothermic and endothermic reactors asdiscussed below.

U.S. Pat. No. 6,306,917 to Mark S. Bohn et al. teaches thathydrocarbons, carbon dioxide, and electric power can be manufactured ata plant using the Fischer-Tropsch (FT) reactors. It also suggests thaturea can be produced from the carbon dioxide but no suggestion is givenas to what facilities or processes are needed to manufacture the urea orthe economic practicality of such a course. U.S. Pat. No. 6,632,846 toSheppard et al. teaches that ammonia, carbon dioxide, hydrocarbons,electric power and urea can be manufactured using FT reactors. Urea isproduced from reacting the ammonia with the carbon dioxide.

In U.S. Pat. No. 4,886,651, Patel et al. describe an integrated systemthat produces methanol, ammonia, and higher alcohols from natural gas.Steam reformers are used to produce streams of gases rich in hydrogen.Nitrogen for the ammonia synthesis is obtained from an air separationunit. The process is not relevant to a coal or petroleum coke feedstock.

In U.S. Pat. No. 6,248,794, Gieskes describes an integrated process forconverting hydrocarbon gas to liquids. The tail gases from theFischer-Tropsch reactor are used only as fuel. Also, the systemsdescribed are not relevant to systems using a solid carbonaceousfeedstock.

In U.S. Patent Application Publication No. 2002/0143219, Price et al.describe a system for converting natural gas to hydrocarbons andammonia. Tail gases from a FT reactor are recycled to the front end to areformer in one example, and tail gases are recycled back to a secondautothermal reformer in another example. Here again, solid carbonaceousfeedstocks requiring gasification cannot be used in this system.

In U.S. Pat. No. 6,586,480, Zhou et al. describe an integrated systemusing synthesis gas derived from coal for producing hydrocarbon liquidsand ammonia. In this system, the FT tail gas is shifted and hydrogenremoved from the shifted tail gases is used in ammonia production.Reforming the gaseous hydrocarbons in the FT tail gases is notconsidered.

The mentioned references deal with economic niches where tax incentives,regulatory penalties and other incentives must combine with otherfactors to make the processes commercial. A continuing increase in worldtemperatures or a firmer tie-in between the CO₂ in the atmosphere andincreasing world climate temperatures could quickly result in suchincentives. The plants can be of particular utility when sited at remotelocations where there is a large surplus of natural gas, petroleum, coalor other carbonaceous materials which are presently unrecoverablebecause of transportation costs, etc.

Increasing regulatory demands have limited, and, in some instancesextinguished, the petroleum producers' and refiners' ability to flarewaste gases. Further, there are often limitations on the amounts andkinds of other wastes that can be disposed of locally without harm tothe environment, e.g., at an offshore crude oil producing platform. Themulti-product plants of this invention provide a mechanism for packagingthe various unit processes required for the utilization of thisinvention in a manner that the resulting plants can be utilized tosupply electricity for a platform, eliminate the need for flares,convert the waste gases and liquids normally flared into liquidhydrocarbons and ammonia substantially eliminating local CO₂ emissions.Solid commercial products can also be produced for agriculture, e.g.,sulfur.

The unit processes of this invention are each individually well knownand the economics of the processes have been commercially proven.However, the joining of these unit processes as taught herein provides autility for environmental and other purposes that has heretofore beenunforeseen.

BRIEF SUMMARY OF THE INVENTION

With the present invention, cleaned syngas generated by gasification ofa carbonaceous raw material with oxygen and produced in an AirSeparation Unit (ASU) is introduced into a Fischer-Tropsch (FT)synthesis unit for production of liquid hydrocarbons. The tail gasesfrom the Fischer-Tropsch reactor containing significant amounts ofgaseous hydrocarbons are reformed in a steam reformer to produceadditional amounts of hydrogen. The CO in the tail gas from the FT unitand in the bypassed synthesis gas is shifted to produce hydrogen (H₂)which, after extraction, e.g., in a hydrogen membrane, and purification,is combined with nitrogen (N₂) from the ASU in the correct ratio forammonia production, typically around a molar ratio of H₂:N₂=3. Thismixture is compressed and introduced into a standard ammonia synthesisloop. After extraction of the H₂, the residual gas can be used for powergeneration, e.g., in a combined cycle power unit. The FT productionrelative to the ammonia production may be adjusted by bypassing more orless syngas around the FT synthesis unit.

As a variation to the above, the FT tail gas may be combined with theby-passed synthesis gas and shifted. Hydrogen removed from the shiftedgas is used in the ammonia synthesis reactor while the remaining tailgases may be used as fuel in a gas turbine combustor.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a simplified flow diagram of the disclosed process ofproducing ammonia and FT liquids.

FIG. 2 is a simplified flow diagram of an alternative process forproducing ammonia and FT liquids.

Before explaining the disclosed embodiments of the present invention indetail, it is to be understood that the invention is not limited in itsapplication to the details of the particular arrangements shown, sincethe invention is capable of other embodiments. Also, the terminologyused herein is for the purpose of description and not of limitation.

DETAILED DESCRIPTION OF THE FIGURES

FIG. 1 discloses a process for producing ammonia, FT fuels and power.Oxygen and nitrogen are separated from air in air separation unit 10.Carbonaceous raw material and water from tank 15 and oxygen from unit 10are introduced into synthesis gas generator 30 as slurry 20. As shown inExamples 1 and 2, a slurry of coal and/or petroleum coke is used. Undersynthesis gas forming operating conditions, synthesis gas 40 comprisinghydrogen, carbon monoxide, carbon dioxide, methane, water, and sulfurcompounds is produced. Although synthesis gas generator 30 is a gasifierin this example, other types of gas generators may be used. Inorganicslag 35 is exported for sale or other uses including disposal.

Synthesis gas 40 is fed to process boiler 50 for steam heat recoverybefore it is introduced into syngas cleaning unit 60 for char removal.Boiler 50 produces high pressure steam 53 while reducing the temperatureof the syngas. Char 63 is recycled to gasifier 30.

Reactor effluent gas, or cleaned syngas 65, is cooled in unit 70 andthen processed through acid gas removal (AGR) unit 80 to remove hydrogensulfide and carbon dioxide. An amine scrubbing system or other AGRsystem known to one skilled in the art may be used. For cooling, atubular heat exchanger or other known systems may be utilized. Processcondensate water 71 and hot boiler feed water 73 are recycledrespectively for plant uses.

Essentially all of the sulfur in feedstock 20 is converted to H₂S duringsyngas generation. Having undergone acid gas removal in unit 80, H₂Sproduced in generator 30 is contained in acid gas stream 83 and may berecovered by utilizing a sulfur recovery system 90. For example, forlarge amounts of sulfur and relatively high H₂S, a Claus unit may beemployed. Since the amount of H₂S produced depends on the sulfur contentof a feedstock, the type of sulfur recovery system required would dependon the desired sulfur recovery efficiency, the quantity of sulfur to beremoved, and the concentration of the H₂S in the acid gas, other typesof sulfur recovery systems should be evaluated to maximize theinstallation of best available control technology. Once recovered,sulfur 95 may be exported. Carbon dioxide 81 from acid gas removal unit80 may be sequestered for sale or for other on-site or off-site uses.

After acid gas removal, further cleaning to remove contaminantsdetrimental to the downstream FT catalyst is required. Synthesis gas 85is passed through guard beds 100 to reduce contaminant levels in thesynthesis gas before it is admitted to the FT reactor. A zinc oxide bedcan be used to remove a few ppm of hydrogen sulfide. Other types ofguard beds and various configuration of beds may be utilized.

A portion 105 of synthesis gas 103 is introduced into Fischer-Tropschreactor 110 where primarily aliphatic hydrocarbons and carbon dioxideare formed. Liquid hydrocarbons 112 from this reaction are separatedfrom Fischer-Tropsch tail gas 117 comprising carbon dioxide, uncondensedhydrocarbons, unreacted hydrogen and unreacted carbon monoxide.Separated FT effluent 116 may be recycled to the slurry preparation tank15. Liquid hydrocarbons 112 undergo product upgrade in reactor 113 wherehydrotreating allows products such as naphtha 114 and diesel 115 to beexported.

A portion 106 of synthesis gas 103 is combined with Fischer-Tropsch tailgas 117 from FT reactor 110 whereby gas mixture 118 is formed. Gasmixture 118 is compressed to an elevated pressure using compressor 120.Compressed gas mixture 125 is then introduced along with steam into oneor more shift reactors 130 to convert a portion of the carbon monoxidein the FT tail gas and water to hydrogen and carbon dioxide. Shiftedgases 135 are introduced into hydrogen membrane separator 150 to producetwo gas streams-stream 151 comprising hydrogen-rich gases and stream 153comprising hydrogen-lean gases. Optionally, absorption unit 140 may beused to remove carbon dioxide from shifted gases 135 before introducingthe gases into hydrogen membrane separator 150. Carbon dioxide from theabsorption unit may be combined for sequestration with the carbondioxide 81 from acid gas removal as denoted by 81 a.

Stream 153 is burned in gas turbine combustor 160 exhausting into heatrecovery steam generator (HRSG) 170. Through HRSG 170, high pressuresteam 173 is directed through steam turbine/generator set 180, e.g., athree-stage turbine mechanically coupled to a generator, during theproduction of electricity. Low pressure steam 181 from the turbine maybe directed to export. Power 185 can be allocated as parasitic power 187to feed the plant or exportable power 189. Steam 171 from HRSG 170 is asource of plant steam.

Stream 151 is compressed to an elevated pressure in compressor 190 andthen introduced into pressure swing adsorption unit 200 to produce astream 205 of high purity hydrogen. Stream 205 together with nitrogenfrom air separation unit 10 is introduced into reactor 210 to produceammonia 215 for sale. A portion 206 of stream 205 is used for productupgrade of liquid hydrocarbons 112 from FT reactor 110.

FIG. 2 discloses an alternative process for producing ammonia, FT fuelsand power. The processes before the introduction of synthesis gas intothe FT reactor are similar to those of FIG. 1. A portion 105 ofsynthesis gas 103 is introduced into Fischer-Tropsch reactor 110 whereprimarily aliphatic hydrocarbons and carbon dioxide are formed. Liquidhydrocarbons 112 from this reaction are separated from Fischer-Tropschtail gas 117. Liquid hydrocarbons 112 undergo product upgrade inhydrotreater 113 wherein products such as naphtha 114 and diesel 115 maybe produced, e.g., for export.

In this alternative process, Fischer-Tropsch tail gas 117 from FTreactor 110 is compressed to an elevated pressure using compressor 310.Compressed FT tail gas 315 is then introduced into steam methanereformer 330. Steam methane reformers typically use natural gascomprising methane, ethane and smaller amounts of other gaseoushydrocarbons as a feedstock. In this embodiment, the methane, ethane,ethylene, propane, propylene, butane, butane and/or small amounts ofhigher hydrocarbons in the FT tail gas serve as feedstock. Hydrocarbonsin FT tail gas 315 and water are converted to reformer effluent 335comprising hydrogen, carbon monoxide, and carbon dioxide. Here, theportion of synthesis gas, which was previously combined with theFischer-Tropsch tail gas from the FT reactor, is introduced into theammonia plant train before shifting occurs. Thus, portion 107 ofsynthesis gas 103 is combined with reformer effluent 335 whereby the gasmixture is fed to shift reactor 340. In the shift reactor, carbonmonoxide is reacted with more steam to produce a mixture of carbondioxide and hydrogen. Shifter effluent 345 is fed into carbon dioxideabsorption unit 350 wherefrom CO₂ is removed. Carbon dioxide from theabsorption unit 350 may be combined for sequestration with the carbondioxide 81 as denoted by 81 b. The product 355 of the absorption unitcontains traces of CO and CO₂ in a highly concentrated hydrogen stream.The carbon dioxide removal unit 350 may use an amine for absorption.Methanator 360 is used to convert the trace CO and CO₂ in stream 335 tomethane. The methanator effluent 365 comprises high purity hydrogen andmethane. Effluent 365 together with nitrogen from air separation unit 10are introduced into reactor 370 to produce ammonia 375 for sale.Adiabatic pre-reformer 320 may be used to remove unsaturatedhydrocarbons, which may form carbon in the reformer, from compressedtail gas 315 prior to introduction into steam reformer 330. The ammonialoop comprising units 330, 340, 350, 360, and 370 may be in an existingammonia plant.

Purge stream 371 is introduced into hydrogen membrane separator 380 toproduce two gas streams-stream 385 comprising hydrogen-rich gases andstream 383 comprising hydrogen-lean gases. Stream 383 is burned in HRSG390. Through HRSG 390, high pressure steam 393 is directed through steamturbine/generator set 400, e.g., a three-stage turbine mechanicallycoupled to a generator, during the production of electricity. Lowpressure steam 401 from the turbine may be directed to export. Power 405can be allocated as parasitic power 407 to feed the plant or exportablepower 409. Steam 391 from HRSG 390 is a source of plant steam.

Stream 385 is compressed to an elevated pressure in compressor 410 andthen introduced into pressure swing adsorption unit 420 to produce astream 425 of high purity hydrogen which is used for product upgrade ofliquid hydrocarbons 112 from FT reactor 110.

Similar to FIG. 1, H₂S produced in generator 30 is contained in acid gasstream 83 and may be recovered by utilizing a sulfur recovery system 90.Once it is recovered, sulfur 95 may be exported.

The following calculated examples are presented to further illustratethe process. Example 1 is based on FIG. 1. Example 2 is based on FIG. 2.

EXAMPLE 1

Two thousand (2,000) short tons per day (STPD) of petroleum cokecontaining 7% moisture are gasified to produce synthesis gas comprisedof hydrogen, carbon monoxide, carbon dioxide, water, methane, nitrogenand impurities. After condensing the water and removal of impurities,the remaining gases are divided into two streams. One stream is fed to aslurry Fischer-Tropsch reactor utilizing an iron-based catalyst. Thetail gases from the FT reactor after liquid product removal arecomprised of hydrogen, carbon monoxide, carbon dioxide, nitrogen,ethane, ethylene, propane, propylene, butane, butene, pentane, pentene,and smaller amounts of higher hydrocarbons. These tail gases arecombined with the other stream bypassing the FT reactor and the combinedgases are fed to a shift reactor to produce hydrogen and carbon dioxidefrom carbon monoxide and water. The gases from the shift reactor are fedto a hydrogen membrane separator for recovering hydrogen. The hydrogenpermeate from the membrane separator is compressed and refined to highpurity using a pressure swing adsorption (PSA) unit. The purifiedhydrogen from the PSA unit is fed to an ammonia synthesis reactor whereit reacts with nitrogen from the air separation unit to produce ammoniafor export. A small portion of the purified hydrogen is used forupgrading the FT products. Off-gases from the hydrogen membraneseparator are used for fuel in a gas turbine combustor. Flue gases fromthe gas turbine combustor provide heat required by the heat recoverysteam generator (HRSG). Steam from the gasifier process boiler, the FTreactor cooling, and the ammonia synthesis reactor cooling are fed tothe HRSG. Electrical power from both the steam turbine and gas turbineis used for plant requirements.

Based on the process described above using 2,000 STPD of petroleum cokeas the feedstock, calculations using in-house software programs showthat the following amounts of FT products and ammonia can be producedfor export:

Synthesis Gas Bypassing FT Reactor Products 0% 50% 100% FT Product, BPD3400 1700 0 Ammonia, STPD 467 1023 1596

EXAMPLE 2

Five thousand one hundred and seventy (5,170) short tons per day (STPD)of Wyoming Powder River Basin (PRB) coal containing 30% moisture aregasified to produce synthesis gas comprised of hydrogen, carbonmonoxide, carbon dioxide, water, methane, nitrogen and impurities. Aftercondensing the water and removal of impurities, the remaining gases aredivided into two streams. One stream is fed to a slurry Fischer-Tropschreactor utilizing an iron-based catalyst. The tail gases from the FTreactor after liquid product removal are comprised of hydrogen, carbonmonoxide, carbon dioxide, nitrogen, ethane, ethylene, propane,propylene, butane, butene, pentane, pentene, and smaller amounts ofhigher hydrocarbons. Approximately 25% of these tail gases are separatedfor use as fuel for the steam reformer described below. Approximately75% of these gases are compressed and fed to an adiabatic pre-reformerfor removal of olefins. The gases exiting the pre-reformer are combinedwith steam and fed to a steam reformer for producing hydrogen, carbonmonoxide, carbon dioxide, methane and water. The other stream bypassingthe FT reactor is combined with the effluent from the steam reformer andthe combined gases are fed to a shift reactor to produce hydrogen andcarbon dioxide from carbon monoxide and water. The carbon dioxide isremoved from the shifted gases and combined with the carbon dioxide fromthe acid gas removal system. This concentrated stream of carbon dioxidecan be sequestered. The remaining gases are fed to a methanator forremoval of carbon monoxide. The remaining gases comprised of hydrogen,nitrogen and methane are combined with nitrogen from the air separationunit and fed to an ammonia synthesis reactor. Ammonia from the ammoniasynthesis reactor is exported for sale. A small purge stream from theammonia synthesis reactor is fed to a hydrogen membrane separator forrecovery of hydrogen. The hydrogen permeate from the membrane separatoris compressed and refined to high purity using a pressure swingadsorption (PSA) unit. The purified hydrogen from the PSA unit is usedfor upgrading the FT products. Off-gases from the hydrogen membraneseparator and the PSA unit are used for fuel in the heat recovery steamgenerator (HRSG). Steam from the gasifier process boiler, the FT reactorcooling, reformer flue gases, and the ammonia synthesis reactor coolingare fed to the HRSG. The superheated steam from the HRSG is used in asteam turbine for generating electrical power for plant usage and forexport.

Based on the process described above using 5,170 STPD of Powder RiverBasin Coal as the feedstock, calculations using in-house softwareprograms show that the following amounts of FT products and ammonia canbe produced for export:

Synthesis Gas Bypassing FT Reactor Products 0% 50% 100% FT Product, BPD5000 2500 0 Ammonia, STPD 666 1652 2636

Although the present invention has been described with reference tovarious embodiments, numerous modifications and variations can be madeand still the result will come within the scope of the invention. Nolimitation with respect to the specific embodiments disclosed herein isintended or should be inferred. Each apparatus embodiment describedherein has numerous equivalents.

1. A multi-product plant for the production of ammonia andFischer-Tropsch hydrocarbons, the plant comprising: an air separationunit comprising an inlet for air and outlets for oxygen and nitrogen; asynthesis gas generator comprising inlets whereby oxygen from the airseparation unit, carbonaceous raw material, and water are introduced tothe synthesis gas generator, and an outlet for synthesis gas, thesynthesis gas generator being adapted to convert the oxygen,carbonaceous raw material, and water under synthesis gas formingoperating conditions into synthesis gas; a cooling unit for cooling thesynthesis gas, the cooling unit comprising outlets for water and cooledsynthesis gas; a means for separating the cooled synthesis gas into afirst portion of synthesis gas and a second portion of synthesis gas; aFischer-Tropsch reactor, the Fischer-Tropsch reactor comprising an inletfor the first portion of synthesis gas, an outlet for tail gasescomprising unreacted carbon monoxide, carbon dioxide, and gaseoushydrocarbons and an outlet for liquid hydrocarbons; the Fischer-Tropschreactor adapted to form primarily aliphatic hydrocarbons and carbondioxide from the first portion of synthesis gas; a compressor comprisingan inlet for the second portion of the synthesis gas and theFischer-Tropsch tail gas and an outlet for a compressed gas mixture; oneor more shift reactors comprising inlets for the compressed gas mixtureand steam and an outlet for shifted gases comprising hydrogen and carbondioxide; the one or more shift reactors adapted to convert a portion ofthe carbon monoxide and water to hydrogen and carbon dioxide; a hydrogenmembrane separator comprising an inlet for the shifted gases and outletsfor a hydrogen-rich gas stream and a hydrogen-lean gas stream; a gasturbine combustor of a combined cycle plant, the gas turbine combustorcomprising an inlet for the hydrogen-lean gas stream, adapted forburning the hydrogen-lean gases to drive a generator mechanicallycoupled to the gas turbine thereby producing electricity; a compressorcomprising an inlet for the hydrogen-rich gas stream and an outlet forelevated pressure hydrogen-rich gas; a pressure swing adsorption unitcomprising an inlet for the elevated pressure hydrogen-rich gas and anoutlet for high purity hydrogen; and a reactor comprising inlets for aportion of the high purity hydrogen and nitrogen from the air separationunit and adapted to produce ammonia from the high purity hydrogen andthe nitrogen.
 2. The multi-product plant of claim 1 further comprisingat least one cleaning unit adapted to remove from the synthesis gas atleast one selected from the group consisting of sulfur compounds, carbondioxide, and char; the at least one cleaning unit comprising an inletfor synthesis gas and an outlet for cleaned synthesis gas, the at leastone cleaning unit positioned upstream or downstream of the cooling unitfor cooling the synthesis gas, and upstream of the Fischer-Tropschreactor.
 3. The multi-product plant of claim 2 wherein the at least onecleaning unit comprises an acid gas removal unit, the acid gas removalunit further comprising an outlet for a stream comprising hydrogensulfide.
 4. The multi-product plant of claim 3 wherein the acid gasremoval unit further comprises an outlet for carbon dioxide.
 5. Themulti-product plant of claim 1 further comprising a product upgradeunit, the product upgrade unit comprising an inlet for at least aportion of the liquid hydrocarbons from the Fischer-Tropsch reactor andan inlet for a portion of the high purity hydrogen from the pressureswing absorption unit, the product upgrade unit adapted for upgradingthe liquid hydrocarbons by hydrotreating.
 6. An integrated system forthe economical production of ammonia via steam methane reforming of agas mixture comprising Fischer-Tropsch tail gases, and for theproduction of liquid hydrocarbons via Fischer-Tropsch reaction; thesystem comprising: an air separation unit comprising an inlet for airand outlets for oxygen and nitrogen; a synthesis gas generatorcomprising inlets whereby oxygen from the air separation unit,carbonaceous raw material, and water are introduced to the synthesis gasgenerator, and an outlet for synthesis gas, the synthesis gas generatorbeing adapted to convert the oxygen, carbonaceous raw material, andwater under synthesis gas forming operating conditions into synthesisgas; a cooling unit for cooling the synthesis gas, the cooling unitcomprising outlets for water and cooled synthesis gas; a means forseparating the cooled synthesis gas into a first portion of synthesisgas and a second portion of synthesis gas; a Fischer-Tropsch reactor,the Fischer-Tropsch reactor adapted to form primarily aliphatichydrocarbons and carbon dioxide from the first portion of the synthesisgas, the Fischer-Tropsch reactor comprising an outlet for tail gasescomprising unreacted carbon monoxide, carbon dioxide, and gaseoushydrocarbons and an outlet for Fischer-Tropsch liquid hydrocarbons; acompressor comprising an inlet for the Fischer-Tropsch tail gas and anoutlet for a compressed tail gas; a steam methane reformer comprisinginlets for the compressed gas and steam, and an outlet for a reformereffluent comprising hydrogen, carbon monoxide, and carbon dioxide, thesteam methane reformer adapted to produce the reformer effluent from theinlet gases; one or more shift reactors comprising an inlet for a gasmixture comprising the second portion of the synthesis gas and thereformer effluent and an outlet for shift reactor effluent comprisinghydrogen and carbon dioxide, the one or more shift reactors adapted forconverting a portion of the carbon monoxide and water in the inlet gasmixture to hydrogen and carbon dioxide; an absorption system comprisingan inlet for shift reactor effluent, an outlet for carbon dioxide, andan outlet for a concentrated hydrogen stream comprising trace amounts ofCO and CO₂; a methanator comprising an inlet for the concentratedhydrogen stream comprising trace amounts of CO and CO₂ and an outlet formethanator effluent; the methanator adapted for converting the CO andCO₂ to methane; an ammonia synthesis reactor comprising an inlet for themethanator effluent, an inlet for a nitrogen stream comprising nitrogenfrom the air separation unit, an outlet for purge gases comprisinghydrogen and an outlet for ammonia; the ammonia synthesis reactoradapted for producing ammonia; a hydrogen membrane separator comprisingan inlet for the purge gases comprising hydrogen, an outlet for ahydrogen rich gas stream, and an outlet for a hydrogen-lean gas stream;a heat recovery steam generator comprising an inlet for at least aportion of the hydrogen-lean gases; the heat recovery steam generatormechanically coupled to a steam turbine adapted for the production ofelectricity; a compressor comprising an inlet for the hydrogen-richgases and an outlet for a compressed hydrogen-rich gas stream; apressure swing adsorption unit comprising an inlet for the compressedhydrogen-rich gas stream and an outlet for high purity hydrogen; and areactor comprising an inlet for high-purity hydrogen, an inlet for theFischer-Tropsch liquid hydrocarbons, and an outlet for upgraded liquidhydrocarbons, the reactor adapted for upgrading the Fischer-Tropschliquid hydrocarbons by hydrotreating.
 7. The integrated system of claim6, further comprising an adiabatic pre-reformer upstream of the steammethane reformer and downstream of the compressor comprising an inletfor the second portion of the synthesis gas and the Fischer-Tropsch tailgas and an outlet for a compressed tail gas.
 8. The integrated system ofclaim 6 further comprising at least one cleaning unit adapted to removefrom the synthesis gas at least one selected from the group consistingof sulfur compounds, carbon dioxide, and char; the at least one cleaningunit comprising an inlet for synthesis gas and an outlet for cleanedsynthesis gas, the at least one cleaning unit positioned upstream ordownstream of the cooling unit for cooling the synthesis gas andupstream of the Fischer-Tropsch reactor.
 9. The integrated system ofclaim 8 wherein the at least one cleaning unit comprises an acid gasremoval unit, the acid gas removal unit further comprising an outlet fora stream comprising hydrogen sulfide.
 10. The integrated system of claim6, wherein the steam methane reformer, the one or more shift reactors,the absorption system, the methanator, and the ammonia synthesis reactorform an ammonia loop of an existing ammonia production plant.